1Z TDI Conversion into Syncro Clutch Upgrades?

[Air Kraft]

Hi there. I have fitted a Golf/Audi 1.9 TDI (1Z) into my Syncro Doka and used the standard Vanagon diesel flywheel and a brand new clutch. All was fine for a couple of thousand miles until I fitted a tuning box to the TDI and upped the hp to 115 (180 ft/lbs of torque) and now the clutch slips like a beeatch!

Anyone have a solution for an uprated clutch setup as the standard 1Z flywheel can't be used as its diameter is larger than that of the diesel Vanagon, so I can't just use the 1Z flywheel and clutch setup...

[MarkWard]

If you don't get a reply here, look over at http://autos.groups.yahoo.com/group/TDI-conversion Most likely some has figured this out. I am using the stock diesel clutch, but drive like I would have to replace it if it starts to slip. You could also contact Clutch Masters. I think you could send them the pressure plate and disc and they can do a stage upgrade. Bummer that it is slipping already and a syncro to boot.

[fairweather]

The VR6 PP will bolt up to the TDI flywheel, you can get a high performance disk from cbperformance.com.You will need to grind/bend two little tabs on the VR6 PP to clear the bellhousing.

I understood that the stock DV bellhousing would accommodate the TDI flywheel, it is the wbx BH that doesn't work. Is the starter on the top or the side? Top mount is the DV, side is wbx. DV BH also requires the use of a syncro diesel gas tank to clear the starter.

If you can't get the TDI flywheel to work you can get a stage II setup (flywheel,PP and disc) from Kennedy Engineering.

[Air Kraft]

Thanks for the prompt replies guys. Fairweather, my truck was orginally a 1.6 turbo diesel and I am using its stock bellhousing. Not sure if it is DV or not, but the starter motor is on top, not at the side. My truck is a syncro, if that helps. The 1Z flywheel is about 7 mm larger in diameter at the ring gear compared to the stock 1.6 TD flywheel, so I assume that it wouldn't work with the stock starter motor setup in the diesel bellhousing? Not sure, I could be wrong as am fairly new to Syncros and diesels...
Just looked at Kenedy's website and they don't seem to list any uprated clutches for Vanagon diesels. Is it a special order item?
Thanks, matt

[MarkWard]

I think he is saying the Pressure Plate from the VR6 will bolt up to the stock diesel flywheel except for two tabs that must interfere with the bell housing when turning. He is also suggesting a disc with better grip. The splines are very common to many VW's and you just need the correct diameter. Interesting.

[Air Kraft]

I don't think the 228 mm VR6 pressure plate can bolt to the 210 mm stock diesel flywheel without extensive machining, although it could be worth a thought!

[anthonywesty]

Try this site; http://www.clutchnet.com/search.php?mode=search
_________________
82' Westfalia 2.0 16V with Digifant.
86' Vanagon GL
http://i223.photobucket.com/albums/dd147/WestyBOYPR/westfaliaCY.jpg

[MarkWard]

I honestly don't know. It is one of those things that I thought I would address when and if it came up. I think when you refer to a 210 flywheel it is actually addressing the clutch disc surface diameter, not the actual diameter of the flywheel. So it could be possible that the bolt holes on the pressure plate line up from the VR6 with a smaller diameter disc. I'd have to have the parts in front of me to tell for sure.

[avdem]

I am running a 1Z in my syncro. Using the 1Z flywheel and a JX bellhousing. To do this you need to machine and rebalance the 1Z flywheel, doing this you can keep the original starter.

[MarkWard]

[Air Kraft]

Hi Avdem. What machining do you have to do to the 1z flywheel?

[BlackDogVan]

Best info i've found so far on the VR6 PP.

http://wiki.club8090.co.uk/index.php/Gearbox_Clutch_CVs_-_Diesel_Uprated_Clutch


FYI dual mass flywheels are to be avoided! Chip tuning a tdi with a Kennedy plate has been discussed a bit, some have had flex issues & recommend using the diesel bellhousing for non stock diesels, I am on my Mtdi.

TDI Flywheel requires custom input shaft but I have yet to hear that the custon input shaft is anything other than a WBX shaft thats been shortened by approx .375".

[anthonywesty]

[Outback Kampers]

Pretty simple.

Toss all the original diesel clutch and flywheel bits.
Then use:

1) Stock 1Z/AHU flywheel - the same diameter overall (ring gear). The only downsides are that the starter nose may/may not contact the flywheel's outer diameter, and several of the oil pan bolts cannot be removed without first removing the flywheel (shold the pan ever need removing). I think that was why one person mentioned machining the flywheel. It's actually simpler to remove a minute amount from the nose of the starter for the necessary clearance.

2) VR6 Jetta 228mm pressure plate - will handle torque up to around 230 ft/lbs and bolts right to the TDI flywheel. As mentioned, there are two tabs the jut outward; carefully tap those flush with the plate from where they were formed.

3) Clutch disc: use the 228mm HD 2.1 wbx disc. Or, if you want to spend a little more, HA Projekt in Germany sells an excellent replacement trans input shaft that allows one to use the TDI disc.

I've done several vans this way and brutally tested (hard tows, snatching vans from snow graves) my own mTDI Syncro with this exact setup and it works fabulous. The beauty is that when time comes for replacement parts you don't need to go to any specialty sources.
_________________
Karl Mullendore
1990 Syncro 16" sunroof Reimo highroof conversion
1990 Westy Multivan 112i automatic
1992 LT31 Karmann Distance Wide 'La Tortuga'
2014 Touareg X TDI

[Outback Kampers]

[Air Kraft]

Hi Westyventures. Do you know whether the 1Z flywheel from an Audi A4 is the same as that from a Golf 1Z TDI? My 1Z came from an Audi and I am pretty sure the outer diameter of the flyhweel (at the ring gear) is about 5 - 7 mm larger than the JX flywheel. I could be wrong... will measure again tomorrow morning. THanks

[Outback Kampers]

[Syncroincity]

I bought the TDI-into-T3 input shaft from Bernd Jager in Germany, and found a nice TDI single-mass flywheel/clutch/PP set cheap on Ebay. I wish I'd known about that adapter input shaft before I spent all day shortening my gasser shaft You can also now use uprated pressure plates and/or puck-style clutch discs for the TDI.
_________________
'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[rotaecho]

Not syncro specific, but think it'll be the same.

I've been researching what clutch to use with a mTDI (1Z/AHU) setup.

I initially got a VR6/G60 SACHs kit from IDParts. Thinking this was the route to go.

However, then I started having doubts after reading http://forums.tdiclub.com/showthread.php?t=276798&page=88 about an ALH/84 vanagon setup I had my doubts and sounded like DMF was the way to go.

After having this thread mellow for awhile, how do people feel about SMF vs DMF ?
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[SyncroGhia]

I would consider the dual mass flywheel.

TDI engines have a nasty habit of killing Syncro transmissions and it's the aggressive nature of the TDi engine that has all of the gears knocking each other together (you can hear it at idle!) that is a large part of that.

The DMF is designed to take a lot of that our and protect your transmission.

A lot of the guys over here are now removing the single mass flywheels and fitting dual mass flywheels instead.

As above, there are a number of options. TDi flywheel machined down with TDi clutch (required TDi input shaft).

TDi flywheel, machined down with VR6 clutch - NOTE: the splined hub on the TDi centre plate can interfere with the clutch release guide tube. Check your individual centre plate.

DMF - requires TDi input shaft.

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD